Catalytic apparatus



Nov. z5,A 1930.

l. HEcHr-:NBLEIKNER CATALYTIC APPARATUS Filed May 18. 192e Patented Nov.215, 1930 UNITED STATES .PATENT OFFICE] ING-ENUIN HiEGHENBLEIKNER, FCHARLOTTE, NORTH CAROLINA, ASSIGNOR, BY MESN'E ASSIGNMENTS, T0 CHEMICALCONSTRUCTION CORPORATION, A CORPORATION OF DEL AWARE cA'rALYTTcAPPARATUS" vApplicationiledl May 18, 1928. Serial No. 278,867.

This invention 'relates to a converter` sysd Atem or catalytic apparatusand' relates more particularly to a converter apparatus for carrying outcatalytic reactioliswin the vapor phase and has special reference to theprovision of a converter system adapted espe-` cially for use in thecatalytic voxidation of sulphur dioxide.

A prime deslderatum of my present invention centersjaboutthe provisionof 1mprovements in converter eystems of the type v disclosed inthepatent to A. O. Jaeger No. 1,660,511 of. February 28, 1928. In catal icapparatus of this type, particularly w en employed for oxidizing sulphurdioxide in the contact methodof producingV sulphuric i acid, it isrequisite'to keep the temperature under control not only in the catalystmass which is subjected tothe fresh gases but also '20 in the lastcatalyst layers which are required to effect the last few percent ofreaction. This is due to the fact that the catalytic reaction isrelatively sensitive to temperature;

and too high a temperature in the last catalyst layers results in areversible reaction or reversion of the gases and hence in an incompleteoxidation process.

To control. he temperature of reactionin the later stages of conversion,it has been 3 suggested to separate the converter system intoA aconverter of relatively large heat generating capacity and one or moreaddition- -al converters 4of lower heat generating capacity separatedtherefrom with heat exchangers ^interposed therebetween for cooling thegases flowing from the first or main r converter where the greatestreaction stakes. place'to the. added,l converter or converters where thelast fewpercent of 'reaction 1s ef- 40.-. fected.- This suggestedsolution of the prob- "lem is, however, incomplete'and only partiallyeffective and'results moreover in an `undesired complication form reacton temperatures, variations in the temperature of the gas iiowleavingthe first converter take` place, rendering it diffcult touniformly control the temperature of the p apparatus. r, Although therstconverter ofthe system is constructed as an-automsvitic gas cooledapj paratus especially` designed to-maintain uniof reaction' in theadded converters of the series or system. The temperature variations inthe main or automatic gas cooled converter' are largely due to the lackofV proportionality between the radiation properties of the converterand the changes in the gas flow through the converter; and for thisreason,` among others, the added converters are separated spacially fromthe lmain converter, this separation minimizing the eX- posure of theadded catalyst layers to the full radiant heat 'of the highly heatedcatalyst mass in themain converter. This sep- \aration of the convertersofthe system reof lower heat generating ca acity, are auto- I maticallycontrolled and pre erably by the reaction heat of the main converter,in- ,suchV a way as to effect a uniform reactlon tempera-v ture intheadded or secondary converters;

and, second, aconvertr system in which vthe converters of the series areinter-related for ei'ecting a temperature control of one convertergoverned by the temperature of a converter preceding the same in theseries, in l such a way as to permitall of the convertersl`offthe'system or series to .be'arranged in a :pingle apparatus `orstructure vinstead of a vlura'lityof separated structures.

j .'To the accomplishment ofv the eforegoing l andsuch .other objects aswitlhereinafter appear, m A and their relation one. to the other-,ashereinafter more sought to be de ned inthe claims reference being had tothe accompanying drawings which show the preferred embodiment of mypresent invention, and in which The gure is a vertical elevationaldiainvention consists in the elements articularly` described and .95 ,Y

grammatic view of the converter system of my present invention.

Referring now more in detail to the drawautomatically cooling the gasesof reaction,

said means comprising preferably a gas cooler D arranged between themain converter A and the first layer converter B and a second gas coolerE arranged between the layer converters B and C.

- The converter structure comprises a shell 10 having a roof or top 11and a bottom 12, the said shell 10 being sub-divided into a plurality ofchambers including a chamber for the main converter A, chambersrfor thesecondary converters B and C with free spaces interposed between thesechambers for the gas cooling means D and E. The top or roof 1l of theconverter structure is provided with an inlet 14 for the entering gasmixture; and the bottom 12 of the converter structure is provided withan outlet l5 for the reaction gases, the gas flow through the converterchambers being as indicated by the arrows shown in the igure.

The main converter A is preferably of the automatic gas cooled type andcomprises a catalytic mass 16 through which the gases are forced afterbeing preheated by the heat exchanging elements 17, 17. The catalystmass 16 is supported on a gas permeable bottom 18; and the heatexchanging elements 17, 17 are embedded in the catalyst-mass 16, each ofsaid heat exchanging elements comprising an open ended tube 19 passingdownwardly through an upper gas impermeable partition 20 into a closedend tube 21, the said open ended tube 19 extending fora substantialdistance in the closed end tube 21 below the level of the 'catalyst mass16.- The closed bottom end tube 2l of each heat exchanging elementextends at its top above the level of the catalyst mass 16 as clearlyshown in the drawings. Suitable bae plates 22, 22 may be provided abovethe eonverter-A arranged in a gas inlet chamber 23. The conn .verter ischarged with the catalyst through orifices in the partition 20 closed byplugs 24 24.

with this recited construction, it will be understood that in enteringthe main converter the gases, after being thoroughly mixed anddistributed by the baille plates 22, move down through the inner tubes19 out of directheat exchanging relation with the catalyst, the gasesafter striking the bottom of the tubes being then caused to reversetheir flow in the heat exchanging elements Aand to move upwardly throughthe tubes 2l in direct heat exchanging contact with the catalyst, thegases being then deflected by the upper partition 20 for movement intoand through the catalyst mass 16, all as indicated by the arrows in thefigure. This main converter A, due to the construction of the heatexchanging elements, possesses substantial cooling properties andeffects an automatic cooling of the gases throughout a substantial rangeof gas velocities.

The converters B and C are substantially similar in construction, eachcomprising a layer 25 of the catalyst supported on a permeable partitionor screen 26, each layer converter receiving the gases from a free spacethereabove, each free space being preferably provided with gas deiectingand mixing baiie plates 27, 27. I

As heretofore stated, it is essential, particularly in carrying out suchexothermic reactions as are met with in the oxidation of sulphurdioxide, to control the reaction temperatures in the added converters Band C within relatively narrow limits so that reversion effects areminimized and complete conversion is produced. Due, however, to a numberof factors including perhaps mainly the lack of proportionality betweenthe radiation properties of the converter A and the variations of thegas velocity therethrough, the temperature in the converter A fiuctuateswith the result that the temperature in the secondary converters B and Cis undesirably non-uniform. Moreover, the converters B and C, beingarranged Acontiguous to the main converter A, are exposed to theradiating heat of the highly heated catalyst mass in the `converter A,this resulting in producing further uncontrolled variations ingthetemperature of the secondary converters. As an example of the desiredtemperature control, it may be stated that with the apparatus thus fardisclosed, the tempera` ture of the reaction gases entering theconverter B is about 820 to 850 F. whereas it is desired that thetemperature of these entering gases be about 775 F. The converter Bbuilds up about 50 F. so that the desirable temperature of reaction inthe con.- verter B is about 825 F. whereas the operation temperature mayundesirably run to 890o F. Similarly thetemperature of thegases'entering the converter C should desir ably be about 700 F. with apermissible -building up of the temperature to 725 F. in

lilla verters A and B and, if desired, between the i converters B and C,and the control of such means automatically by the temperature oposition such heat exchanging means.

have discovered that by means of`this,ar rangement and method ofcontrol, the ef fects of radiation from the converter A may becompensated for and the temperature of the gases in the secondaryconverters may be made uniform irrespective of the fluctuations in thetemperatures of the main converter A.

These'results I accomplish by the provisionof the gas cooling means Dand E arranged in one or both of the free gas spaces between theconverters. The gas cooling means D and 'E are substantially similar' inconstruction and mode of control and a description of the gas coolingrmeans D will therefore suiice for both, the parts of the gas coolingmeans E being designated by ref` erence characters similar (but primed)to those applied to the parts of thegas cooling means D. The gas coolingmeans preferably l comprises an annular air circulating chamber 28having an extensive area in the free 'gas space in which" it is placed,the said annular vchamber comprising an air cooled jacketvfor the freespace having an air inlet 29 and an air outlet 30. .For .cooling the`gases, the air circulates through this annular chamber in the directionsshown by thearrows therein. For governing the temperature ofthe gases tobe cooled, the velocit of iiow of the air circulation in the coo ingmeans is controlled by a temperature regula# tor generally designatedlas 31, said temperavture regulator comprising a regulator bulb i 32inserted into the catalytic mass 16 of the converter A' connected bymeans of a flexible conduit 33 towa head 34 ofthe regulator, the saidhead having abellows construction (not shown) which controls the openingor closa ing of a valve stem 35 connected to the valve 4:3 f known makeand does not'form part of my change in the temperature in the con-` 36.The regulator-structure is lof a wellpresent invention. With thisapparatus, any

verter IA above or below the point at which the'instrument is set isimmediately transmitted to the bellows which by expanding andcontracting closes or opens` the valve 36, thereby regulating the flowofthe cool.-

ging air or gases, the ov erationbeing such that the temperature o thereaction gases ente'ri'rngthe secondary converter orconverters 1smaintaineduniform within narrow limlts.

The use and operation of the convertersysvtem of my present inventionand the many advantages thereof including those herein above set'forth', will now bel fully apparent from the above detaileddescription thereof. .'It will further be apparent that while I have'fshcwn and described my invention in the preferred form, many changesand modifications may be made in thel structure disclosed withoutdeparting from the spirit ofthe innvention. defined in the followingclaims.

I claim:

1. A converter system comprising a rst converter of large heatgenerating capacity provided with a catalyst and with automatic coolingmeans for controlling the converter temperatures, a second .converter oflower heat generating capacity connected in cascadev to the exit end ofthe irst converter, gas cooling means interposed between two converters,f

and means controlled by the temperature in said first converter forgoverning the opera.- tion of the said gas cooling means so as to reg,-ulate the temperature of. the gases leaving the' first converter andentering the said second converter.

2. A converter system comprising an automatic gas cooled converterincluding a catalytic chamber, a catalyst mass therein, a gas permeablebottom supporting said catalyst, a gas impermeable partition'above'thecatalyst mass, upright -tubes having closed bottoms, at least a portionof the tubes being im-' bedded in the catalyst and the open ends beingbelow the gas impermeable upper parti tion, open ended tubesl passingdownwardly through the upper partition it the closed 95 end tubes andextending for a sub .tantial distance therein below'the level of thecatalyst, mea for causing reaction gases to ass downwardly. through theopen ended tu es,

upwardly through the closed ended tubes, 1,50'

35 A converterV system comprising a confno,

verter container sub-divided into at least two converter chambers andafree gas space between the converter chambers, a converter in the rstchamber provided with a catalyst and withl automatic cooling means forlcon- Y trolling the temperatures therein, a converter in saidsecondchamber-Lof lower heat gener-l ating capacity'than the firstconverter, gas cooling means-arranged in said'free gas space between theconverters and means controlled 12 by the'temperatureof the firstconverter for governing the operation of said gas cooling means so as toautomatically regulate the tem-y perature of the gases entering saidsecond converter. u f s 1,35

4. A converter system comprising a con verter container sub-divided intothree conl verter chambers and free gas spaces between the converterchambers, a converter in lthe first of said chambers provided with acata- ,'35

lyst and with automatic cooling means for controlling the temperaturestherein, converters in said other chambers of lower heat generatingcapacity than the first converter, gas cooling means arranged in atleast one of said free gas spades and means controlled by thetemperature of a converter preceding said gas space for governing theoperation of said gas cooling means so as to automatically regulate andkmaintain substantially constant the temperature of the gases enteringthe converter succeeding said gas space.

5. A converter system comprising a converter container sub-divided intoatleast two converter chambers and a free gas space between theconverter chambers, a converter in the first chamber provided with acatalyst mass and withautomatic gas cooling means for controlling thetemperatures therein, a converter insaid second chamber of lower heatgenerating capacity than the rst converter and provided with a catalystlayer, and gas cooling means arranged in said free gas space between theconverters operable to regulate the temperature of the gases leavingjthe first converter and entering said second converter. v

6. A converter system comprising a container subdivided into at leasttwo converter chambers and a free gas space between said converterchambers, an automatic gas cooled converter in the firstaof saidchambers in'-- cluding a catalyst mass, heat exchanging elements atleast partially embedded in the catalyst mass, means for causingreaction gases to circulate through the heat exchanging elements out ofdirect heat exchanging relation with the catalyst, means for causing thegases to reverse their flow in the heat exchanging elements and to passin reverse flow through portions of the elements in direct heatexchanging contact with the catalyst and means for defiecting gasesissuing from the heat exchanging elements through the said catalystmass, a converter of the layer type and of lower heat generatingcapacity in the second of said chambers, means for causing the reactiongases-to pass in series first through the automatic gas cooled converterand then through the converter of lower heat generating capacity, gascooling means arranged in the free space between the two converters andmeanscontrolled by the temperature of the first converter for governingthe operation of the said gas cooling means so as to regulate thetemperature of the gases entering the said second converter.

7. A converter system comprising a container sub-divided into at leasttwo converter chambers and a free gas space vbetween said converterchambers, an automatic gas cooled converter in the first of saidchambers including a catalyst mass, heat exchanging elements at leastpartially embedded in the catalyst mass, means for causing reactiongases to circulate through the heat exchanging elements out of directheat exchanging relation with the catalyst, means for causing the gasesto reverse their flow in the heat exchanging elements and to pass inreverse flow through portions of the elements in direct heat exchangingcontact with the catalyst and means for defiecting gases issuing fromthe heat exchanging elements through the said catalyst mass, a converterof the layer vtype and of 'lower heat generating capacity in the secondof said chambers, means for causing the reaction gases to pass in'series first through fthe automatic gas cooled converter and thenthrough thc converter of lower heat generating capacity, and gas coolingmeans arranged in the free space between the two converters and operableso as to regulate the temperature of the gases exiting the firstconverter and entering the said second converter.

8. A' converter system comprising a converter container sub-divided intoat least two converter chambers and at least one free gas space betweensaid chambers, a converter in the first of the chambers provided with acatalyst and with automatic cooling means for controlling thetemperatures therein, a second converter in the second of said chambersof lower heat generating capacity than the first converter, an annularair circulating chamber in said free gas space having air inlet and airoutlet means, and means controlled by the temperature of the firstconverter for governing the flow of air through said inlet means so asto regulate the temperature of the gases entering the said secondconverter.

9. converter system comprising a converter container subdivided into atleast two converter chambersand at least one free gas space betweensaidchambers, a converter in the first of the chambers provided with acatalyst and .with automatic gas cooling means for controlling thetemperatures therein, a second converter in the second of said chambersof lower heat generating capacity than the first converter, an aircooled jacket having an extensive areaV in said free gasspace, an airinlet and an air outlet for said jacket, and means controlled by thetemperature of the first converter for governing the flow of air throughsaid inlet so as to regulate the temperature of the gases fiowingthrough said free gas space and entering the said second converter.

10. A converter system comprising a first converter of large heatgenerating capacity, a second converter oflower heat generating capacityconnected in cascade to the exit end of the first converter, gas'eoolingmeans interposed between two converters, and means controlled by thetemperature in said first converter for governing the operation of thesaid gas coolingqmeans so as to regulate the temperature ofthe gasesentering the said second converter.

l1. A converter systemcomprising a container sub-divided into twochambers and an intermediate free gas space, an automatic gas cooledconverter in the first of said chambers including a catalystl mass, agas permeable bottom supporting said catalyst, a gas impermeablepartition above the ig, catalyst, upright tubes having closed bottoms,at least a portion of the tubes being imp bedded in the catalyst and theopen ends being below the gas impermeable upper partition, open endedtubes passing downwardly' m through the upper partition into the closedend tubes and extendingfor a substantial distance therein below the'level of the catalyst, means for causing reaction gases to passdownwardly through the open ended tubes, upwardly through the closedended tubes, and then downwardly through the catalyst mass, a converterof lower heat generating capacity in the second of said chambers, gascooling means in said free space loe-- tween the two converters;l andmeans controlled by the temperature of the first con-y verter forgoverning the operation of the said gas cooling means so as toautomatically regulate the temperature of the gases entering the saidsecond converter. Signed at Charlotte, in the county of Mecklenburg, andState of North Carolina this 16th day of May A. D. 1928.

lNGENUIN HECHENBLEIKNER.

